Winnebago Roof FAIL!! Adding Steel to a Foam Roof
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- čas přidán 5. 09. 2024
- I did not expect this series to be so long.
It really seems like these Minnie Winnie roofs were not built and engineered to last long. I am very surprised Winnebago put out such low quality in a vital component. I am even more surprised there is not a lawsuit.
This episode has Chad build trusses/frames/supports for the roof while I cut out the foam in order to receive the structure.
So join us as we make plans and try new things, make a tool, and learn a skill.
The gun can be found on amazon here:
amzn.to/3e5HVyp
OMG, the soldering iron hack is brilliant!
I was very surprised how well it worked
Brilliant! Much respect for a quality repair. OEM should be ashamed.
I think Winnebago should be ashamed too!
You guys rock!!’ Man Winnebago dropped the ball what a crappy roof
Thank you. I'm amazed we have to do this too
When we were shopping for our past RV, we really had our hearts set on a Minnie Class C.
I climbed on the roof, and it was in worse shape than this one.
The sales guy didn't know it (nobody climbed up to check the roof), and he didn't care about fixing it as a condition of sale to us because "other people will jump at this unit as is"...
You guys do good work! Isn't it amazing all of the improvements that need to be made to factory builds.
thank you! It's very disappointing to be honest.
Great re-engineering job James. I am happy that you are a business that does things right. Enjoyed the video. Happy trails!
Thanks Phil!
They need you designing their roof construction at the factory, James! I guess that it comes down to how cheaply they can make it?
I'm very shocked about this roof design. Winnebago uses good engineers and CAD but I think they did math wrong on this design.
Wow the trick hot knife, great Video on the roof repair can’t wait for the next part. Stay Safe ✌🏽
Thank you!!
Very nice fix, that RV will leave your shop better than new!
That's the plan!
Very slick repair
thank you!
I’m adding to my knowledge base - What a great repair! Thanks!
Glad it was helpful!
4 more inches ,,, dam ! thats what all the girls ask !
Great vid men ,,,, This is the stuff you just dont see !
Thank you!! :)
I just did something similar to a Monaco S series. There were already three sections of the roof that were 1.5" box steel, but that left 2 sections that were only foam and a small pieces of wood. I added 12 pieces of 1.5" box steel to fill in these sections (with cut down 2x4s a foot off center to create the curve). I still have to add the curved roof supports. All of this is being done from the inside since the coach is getting a full refit.
wow, that's a lot of work!!
@@AZExpert It's not the cleanest work on a 20 year old coach either. I wanted an EPA free coach and I knew that anything that old was going to need a lot.
James, I'm not feeling that the wood did much other than add weight. That is, unless you are planning to drill oversized holes through the steel tube and screw into the wood only.
Either way, You Be The Man! Awesome thinking of cutting the foam with the soldering iron. Have you ever welded plastic with one?
Respectfully, Kevin.
I have had to melt and weld holding tanks with an iron before too. The wood is there for some strength and to prevent deformation on the steel somewhat. We were going to weld aluminum rafters rather than screw steel, but the steel felt stronger and quicker by far.
Okie dokie, this video just answered all my questions i just asked on another of your videos, awesome and thank you!!!!
hot knife trick is brilliant Thank You
I was very surprised it worked too.
Seems like a lot of work ($) for an olde RV... ? I agree with you on the lawsuit. Surprised there has not been a class action suit of some type on this junk design roof
It's only 6 years-old, but yes a great deal of work indeed.
Love the way you make tools 🔧 that work i am with you never cur foam if you can make a 🔥 knife to use even if its home made way to go
I did try to find a good commercial tool, but could find one for what I needed. I was shocked how well it worked. I tried a 150watt iron first and it was very slow.
Amazing job.
Question...What do you think about next time doing something like this, actually bringing the roof over the side by about 3" and putting a crown on it that way water will always run off and over the edge and it would help protect the awnings and slide outs. You can run those pipes through a bender to make a crown, use more pipes and then you can use the aluminum pipes instead of steel and then use a solid sheet of aluminum for the roof. I guess it would be like a prevost bus roof with a overhang.
I'm not sure I would be comfortable changing the design that substantially. I would help though.
@@AZExpert I was just wondering....It just amazes me that you would think that all of these Rv/bus manufactures would come up with a better longer lasting roof for these coaches instead of something you have to fix and inspect every 6 months. they should all be made like the roofs on the old yellow school bus. There has to be a better way to do all this stuff.
You guys really out-did yourselves on this one....excellent work..
thank you very much!
Great job guys. And what a great idea on the hot iron James. Looks fantastic!
Thank you very much!!
Wow!! RV owners are very fortunate to have you and Chad. You guy's have gone above and beyond to correct deficiencies found in the RV manufacturing industry. Is this particular roof problem a one off or are all Winnebago roofs lacking adequate support?
By the sound of it, this particular roof design on the Minnie Winnies is very prone to failure on the longer models.
I've watched many of your videos. Thank you for taking the time to make them. I have seen you use various calks on Winnebago roofs. what is your latest recommendation for the Radius, front and rear caps and roof vents. What brand and types are the best? BTW, I have a 2003 Adventure 33.
I have a number of videos on Winnebago roofs. I recommend proflex clear on the radius
Impressive!
Thanks!
Wow! Amazing solution and execution. What kind of lip do the notched ends sit on, and how do you secure them there?
They will be secured with heavy duty screws. The lip is resting on the extruded profile of the aluminum header
This project hurts my head, but it is utterly fascinating.
I'm sorry to hear that, but that you!
I’m figuring there is more to come however when I saw the steel I was trying to figure out how you were going to tie this all together. Then it magically came together. So after the wood and Filon will the interior ceiling be attached to the installed ribs? You/Chad or both of you came up with an affordable alternative. I’m certain this will help many people. My hat it off you the both of you
Thank you. I thought about screwing the ceiling to the frames, but the logistics of lining the trusses on the ceiling panel seams was untenable. The A/C and vents actually do squeeze the ceiling and the roof together. We also glue the ceiling to the foam using expanding foam adhesive from above before we laminate. Thanks!
Another smart idea by James. You do a better job engineering the roof than the cheap company. Stay safe, the porn music part was funny thanks.
thank you for both compliments!
Somewhat surprised you didn't center notch and then arch the cross beams a couple of degrees just to make a bit of a false crown. It would improve rigidity a bit too.
I did think about it, but the filon will only conform to uniform soft curves or will delaminate quickly. I do not want to do this again for free
I have done something very similar when replacing rotten OSB on a laminated floor system. Mine turned out well and I bet yours will too. Good job guys. if I had started my CZcams channel 20 years ago maybe some of the really cool jobs would be recorded for posterity. Would that have been before CZcams? How old is CZcams?
That's great news!! I have more hope for this repair then. I took many photos but didn't start videos until a few years ago. I did a couple complete Winnebago sidewall replacements too and that woud have been awesome to see.
@@AZExpert No matter how it turns out, it will be way better than it was before you and Bad Chad worked your magic on it.
Got the carpet out in mine, living area has been gutted and not a straight screw in the place.
Sounds about right!
Thank you
You're welcome
Love the styrofoam cutter! I don't have the steady hand, though, so if I try this I might need to make a cradle ri keep the wire straight and steady. Too bad they don't have low- cost carbon fiber structural pieces at the Home Depot. Great video!
I think carbon fiber may have made this repair too expensive to attempt. :)
@@AZExpert which is why the local Home Depot doesn't carry then. I'm hoping that someday they'll be made in volume production so that they can be an alternative to wood or metal structure.
Great video with a lot of creative engineering.... Great idea to put wood in there, you probably could have gotten a much thinner wall with that composite, although super thinwall square tubing is relatively hard to get. But, man, for the price of these things, you all sure have to re-engineer a lot.
A couple of thoughts - putting the long edge vertical instead of flat would make it stronger, although it looks like there was a depth issue - probably could have gotten away with 1x1 instead of 2x1. Putting a crown in it would def make it way stiffer allowing for smaller tubing (esp with the wood inside), but good point about the foam, although it seems to be sagging as much as a crown.... You can use one of harbor freight's bending tools to put crowns in square tubing but you have to modify/make a die. Someone probably sells a set of square dies for those tools.
I did think about a crown, but the lamination process is not forgiving with uneven surfaces. While the thick wall is nice for strength, we really wanted thick walls to hold screws from the deck better without stripping. Thanks!
I'm sure what you've done is very beneficial. However, with the steel trusses spanning across the roof parallel with the sandwich panels, some secondary wood beams spanning between the steel trusses would be helpful. They would support the panels and transfer the load to the steel trusses. Required particularly where the strength of the panel is compromised by vent openings.
Thank you. It may not seem like it, but foam laminated well has a great deal of strength too. The steel is also glued to the foam underneath. Hopefully it will make sense in the next video.
If you want stiff and light you use carbon. You can get carbon tubes that are much stiffer than steel and are much lighter. Sadly that roof was junk out of the factory. And you were right about the roof needing a crown. Have you considered making some profile plates out of aluminium and hot wire cutting crown shaped foam out of 8ft long 2ft wide styrene. Once you had that setup you could churn out identical pieces. Have a look at how RCers cut foam wings. (I know steel is cheap and easy to get)
that would be a big but interesting project for sure
7/11 beer cooler with siding
PRetty expensive cooler
Pretty cool fix. I'm wondering if the walls are plumb and square.
Thank you. As plumb as square as possible.
Metal decking ribbed roofing material should be installed by winebego .
The roofs arent designed to hold much at all
And the saga continues 🤦🏼 Oh Winnebago why?
I was thinking that the whole time.
Seem to repair Winnebago roofs a lot. They the worst ones?
The most unique roofs, so I guess the worst
@@AZExpert you keep teaching us what to look out for
A++++
Love the job. How much weight did the steel add to the RV? Would aluminum extrusion worked as well, been lighter?
The plan was for aluminum, but even the thick wall stuff flexed substaintially more than the steel. I'd the steel added 350 pounds. The thicker luan added 40 or so.
Would aluminum sheeting be too heavy on this kind of roof?
Yes. They don't support much
Would that wood inside the steel also help prevent some of that potential for thermal bridging?
I think it will help a little on thermal transfer too.
Yup Wig Wam Tell No Tale. On they Secret Cooler Roof Design ~ ya good Old Petrified Wood . Time to invest in a band saw, why roof cross rib so flexible think i stick to the Class A Now
I did try my portable metal band saw, the steel was just too wide for the throat. Ultimately the grinder worked well.
23:18 ahahahahaha !
Is it sad that I put so much effort into that? I appreciate you enjoying it!
is it true Winnebago uses 1 2x4 to built 3 trailers
Sounds right
Good repair so far but when the RV is driven and the roof flexes the Styrofoam will rub against the steel trusses and be very squeaky. Winnebago should be sued and the customer reimbursed.
The steel is also glued to the foam with expanding foam adhesive so hopefully that would happen. The deck will also be glued to the foam but also screwed to the metal. I'm throwing everything I can at it to help. Thanks!
Soldering gun used as a hot knife was a good idea, it's basically the same thing they use to cut foam all through out different industries.
Another repair many would have passed on, at this point I think you may have a little masochist in you...LOL
I do like punishing myself it seems
Which video precedes this for background?
czcams.com/video/Mc4GH7TviHU/video.html
When reading imperial measurements of a tape you need good eyesight, I think I will stick with metric
It does make more sense...I just cannot imagine we'll ever switch completely.
@@AZExpert we haven’t switched completely,still have miles,most older still think in feet and inches,and pounds and stones not kilo and grams,I worked on a building site everything was decimal but I am 6 foot tall and 13 stone, I think future generations will be metric,but still using MPH not KPH,I don’t think the government want to change all the road signage and cars MPH
That's gonna rust
It's fine
When he don’t like your comment he just deletes it can’t take negative comments
why would I let strangers make a mess in my house?
Ninjia Monk ? LOL.....
it's very rare and intense training. :)
This episode made me feel sorry for you.
This job is pretty fun right now.
Another over priced, poorly engineered and cheaply made pile of crap. Decor and paint IS just lip stick on a pig. An ALL metal or one piece fiberglass roof IS the only way for RV's to ever be built. Boycott the ceaply made RV Industry, it cost consumers tooooo much in out of pocket repairs down the road.
you'll get no argument from me!
rv manufacturers should pay you to stop making videos
They can try